Service Letter SL13-583/KEL Action code: WHEN CONVENIENT MAN Diesel & Turbo H. Christoffersensvej 6 4960 Holeby Denmark Phone: +45 54 69 31 00 Fax: +45 54 69 30 30 [email protected]www.mandieselturbo.com MAN Diesel & Turbo Niels Juels Vej 15 9900 Frederikshavn Denmark Phone: +45 96 20 41 00 Fax: +45 96 20 40 30 [email protected]MAN Diesel & Turbo Branch of MAN Diesel & Turbo SE, Germany CVR No.: 31611792 Head office: Teglholmsgade 41 2450 Copenhagen SV, Denmark German Reg.No.: HRB 22056 Amtsgericht Augsburg Dear Sirs and Madams In 2012 MAN Diesel & Turbo issued Service Letter SL12-560/SIC re- garding a Mk 2 update for the L16/24 engine. The product has been a success. However, engine operators have observed certain issues after the up- date. Very often, these issues are not related to the Mk 2 package or the engine, but rather to the external treatment systems. Based on the success of the Mk 2 update, MAN Diesel & Turbo, Hole- by, has decided to continue to offer Mk 2 units as an attractive kit, ideal for use at the time of a major overhaul of a Mk 1 L16/24 engine. Yours faithfully Mikael C. Jensen Vice President Engineering Kjeld Lorentzen Superintendent Design Warrenty L16/24 Mk 2 Update Package SL13-583/KEL April 2014 Concerns Owners and operators of MAN Diesel & Turbo four-stroke diesel engines. Type: L16/24 Summary Replacement of SL12-560/SIC regard- ing Mk 2 update for L16/24 Enclosures: Working Card 505-01.20 (13) Working Card 507-01.20 (15) Working Card 508-01.00 (15) Plate 50501-19H Plate 50502-11H Plate 50515-11H Plate 50601-27 Plate 50705-25H Plate 50801-13H Plate 51402-12H Plate 52000-13
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MAN Diesel & TurboBranch of MAN Diesel & Turbo SE, GermanyCVR No.: 31611792Head office: Teglholmsgade 412450 Copenhagen SV, DenmarkGerman Reg.No.: HRB 22056Amtsgericht Augsburg
Dear Sirs and Madams
In 2012 MAN Diesel & Turbo issued Service Letter SL12-560/SIC re-garding a Mk 2 update for the L16/24 engine. The product has been a success.However, engine operators have observed certain issues after the up-date. Very often, these issues are not related to the Mk 2 package or the engine, but rather to the external treatment systems.
Based on the success of the Mk 2 update, MAN Diesel & Turbo, Hole-by, has decided to continue to offer Mk 2 units as an attractive kit, ideal for use at the time of a major overhaul of a Mk 1 L16/24 engine.
Yours faithfully
Mikael C. Jensen Vice PresidentEngineering
Kjeld LorentzenSuperintendentDesign Warrenty
L16/24Mk 2 Update Package
SL13-583/KELApril 2014
ConcernsOwners and operators of MAN Diesel & Turbo four-stroke diesel engines.Type: L16/24
SummaryReplacement of SL12-560/SIC regard-ing Mk 2 update for L16/24
The Mk 2 update kitBased on our service experience since the introduction of the Mk 2 update with SL12-560/SIC, the complete update kit of a Mk 2 cylinder unit now includes:
• Reconditioned complete cylinder unit• Camshaft section (valve)• Connecting rod bearing• Gasket set• Fuel nozzle (Woodward or L’Orange)• New pages for instruction manual• Tool for adjustment of roller guide bracket• Tool for easy and safe adjustment of valve clearance.
PriceThe price for the above-mentioned Mk 2 package is EUR 5,400 Incoterms 2010 ex works Frederikshavn.
RecommendationsThe following points should be observed and consequently, we strongly recommend:
• Installation of 25 µm fuel safety filter according to SL13-577/KEL• Lube oil treatment according to SL13-582/KEL• Installation of the Mk 2 update kits by an MAN Diesel & Turbo authorised workshop.
We reserve the right to reject any claim for the Mk 2 parts, if the above-mentioned recommendations are not followed.
Overhaul of engineIn order to have a fully overhauled engine − a basis for having a well performing engine − we highly recommend to check and/or overhaul the following engine parts at the same time as the Mk 2 update:
• Fuel equipment• Turbocharger• Charge air cooler• Thermostatic valves (water)• Engine room ventilation/pressure• Check of conical elements.
Return of replaced unitsReplaced cylinder units must be returned to MDT/Frederik-shavn for reconditioning within 60 days after receiving the Mk 2 units. If the replaced units are not received at our workshop within 60 days, we reserve the right to invoice the owner EUR 7,000 per cylinder unit. The replaced units must be pro-tected against corrosion and mechanical damage during the stay on board and during transportation by the buyer. If the returned parts are damaged at arrival to the workshop, MAN Diesel & Turbo reserves the right to invoice the buyer an ad-ditional EUR 3,000 per cylinder unit.
How to orderTo order the complete Mk 2 update kit as well as the strongly recommended 25 µm fuel safety filter and installation and commissioning assistance, please contact:
This Service Letter is valid until 31 December 2015.
Safety precautions
Engine stoppedShut-off starting airShut off cooling waterShut off fuel oilShut-off cooling oilStop lub. oil circulationPress Blocking - Reset
Short Description
Dismantling and mounting of valve guide, for inletand exhaust valve.
Starting Position
Valve spindle has been removed 505-01.05
Related Procedure
Mounting of valve spindles 505-01.05
Qualified Manpower
Duration in h : 3/4Number : 1
Data
Data for pressure and tolerance (Page 500.35)Data for tightening torque (Page 500.40)Declaration of weight (Page 500.45)
Special tools
Plate No. Item No. Note52005 120
Hand ToolsHammer / lead hammerNitrogen (N2) or similar
Replacement and wearing parts
Plate No. Item No. Quantity
50501 076 4/cyl.50501 088 4/cyl.
MAN Diesel & Turbo
Work CardPage 1 (2) Replacement of valve guide
505-01.20Edition 13
L16/24
2012.03.12. - version 2008
General
If the clearance exceeds the shown max. limit, (seepage 500.35), the valve guide must be replaced.
Dismounting of valve guide
1) Knock the valve guide out from the bottom ofthe cylinder head, by means of a mandrel,which has a shoulder turning that fits into thevalve guide, see fig 1.
2) Clean the bore of the cylinder head carefully.
3) Inspect for marks that can prevent mounting ofnew valve guide.
Figure 1: Dismounting of valve guide
Mounting of valve guide
1) Before mounting - cool down the new valveguide to approx. -195°C with nitrogen or simi-lar.
2) Insert the valve guide into the bore.
3) Slightly pres-in the valve guide until the shoulderbear against the cylinder head, see fig 2.
Note: Carefully control that valve guide shouldershave full contact to the cylinder cover.
Figure 2: Mounting of valve guide
4) Insert a new O-ring in the valve guide, beforemounting of the valve spindle. Correct mounting can easily be done by the useof two valve spindles as mounting tool, onespindle to be used as support and the otherspindle to be used for pushing the O-ringdownwards, see fig 3. Screw-drivers or other sharp tools should neverbe used for this purpose.
5) For mounting of valve spindle, please see work-ing card 505-01.05.
Figure 3: Inserting a new O-ring in the valve guide
MAN Diesel & Turbo505-01.20Edition 13
Replacement of valve guide Work CardPage 2 (2)
L16/24
2012.03.12. - version 2008
Safety precautions
Engine stoppedShut-off starting airShut off cooling waterShut off fuel oilShut-off cooling oilStop lub. oil circulationPress Blocking - Reset
Short Description
Nominal adjustment of camshaft. (Adjustment ofcamshaft in relation to crankshaft).
Starting PositionCamshaft assembled as per timing order, moun-ted in frame and roller gear house. If intermediatedgearwheel must be changed, the generator mustbe dismounted.
Related Procedure
Qualified Manpower
Duration in h : -Number : -
Data
Data for pressure and tolerance (Page 500.35)Data for tightening torque (Page 500.40)Declaration of weight (Page 500.45)
Work CardPage 1 (4) Adjustment of camshaft for valve and injection timing
507-01.20Edition 15
L16/24
2013.06.19 - version 2008
Assembly of gear wheels for valvecamshaft and injection valve camshaft,without mounted flywheel
Following description is for mounting the gear-wheels in the control drive when alternator, flywheeland cover on coupling side are dismantled from theengine.
Mounting of intermediate gearwheels
1) Turn the crankshaft to top dead centre for thelast cylinder (the cylinder nearest to the couplingside).
2) Mount the upper intermediate gearwheel.
1 Small holes
Figure 1: Marks on gearwheels
3) Mount the lower intermediate gearwheel so themarks on the lower intermediate gearwheel arecorresponding with the mark on the crankshaft
gearwheel, see fig 1(E2). At the same time turnthe upper intermediate gearwheel so that thesmall holes in the circumference of the twointermediate gearwheels are corresponding, seefig 2.
1 Upper intermediate spurwheel
2 Small holes
3 Lower intermediate spurwheel
4 Crankshaft
Figure 2: Position of small holes in the circumference of the twointermediated gearwheels
Note: The punch mark on the crankshaft gearwheelis placed on the 13 teeth counting counter clock-wise from the joint of the gearwheel, see fig 3.
MAN Diesel & Turbo507-01.20Edition 15
Adjustment of camshaft for valve and injection timing Work CardPage 2 (4)
L16/24
2013.06.19 - version 2008
a 13 teeth
Figure 3: 13 teeth counter-clockwise from the joint of the gear-wheel
4) Tighten up the intermediate gearwheels. Tight-ening torque, please see page 500.40.
Mounting of gearwheel for valve camshaft
1) Before mounting of the gearwheel, the markson the crankshaft and the lower intermediategearwheel must correspond, see fig 1 (E2).Futher, the small holes on both intermediategearwheels must correspond.
2) Turn the valve camshaft, until the mark on thegearwheel for valve camshaft corresponds withthe 2 marks on upper intermediate gearwheel,see fig 1 (E1).
3) Tighten up the gearwheel. Tightening torque,please see page 500.40.
Mounting the gearwheel for injectioncamshaft
1) Before mounting the gearwheel, must marks forcrankshaft and lower intermediate gearwheelcorrespond, see fig 1(E2). Secondly must thesmall holes for both intermediate gearwheels becorresponding.
2) Turn the injection valve camshaft, until the markon the gearwheel for valve camshaft corre-spond with the 2 marks on upper intermediategearwheel, see fig 1 (E1).
Note: Adjustment of injection valve camshaft is nowneeded, please see separately chapter “Adjustmentof Fuel Injection Camshaft / Injection Timing”.
Measure of fuel pump lead
1) Dismantle covers for fuel camshaft and fuelpump.
2) Check the mobility of the regulating device.
3) Position the support of the measuring tool onthe two bolts of the camshaft covering. Slip onthe distance sleeves and fasten to the cylindercrankcase by means of hexagon nuts.
Note: During attaching, pay attention to the correctfitting position of the contact point.
4) Insert the dial gauge into the support.
5) Turn the engine until the cam base circle isreached (approx 40° BTDC).
6) Set the dial gauge to "Zero".
7) Turn the engine until the TDC mark (ignition DC)for the actual cylinder is reached. Read the dial gauge and note down the gaugevalue in sheet.
8) Determine the values for the other cylinders inthe same way. Calculate the average value of all measure-ments.
9) Compare the calculated value determined withthe value mentioned below.
10) If the values exceeds the limits, an adjustmentmust be done in order to correct the errors.
11) Remove the complete measuring tool.
12) Mount all camshaft covers.
Plunger lift (average value): see figure.
MAN Diesel & Turbo
Work CardPage 3 (4) Adjustment of camshaft for valve and injection timing
507-01.20Edition 15
L16/24
2013.06.19 - version 2008
Pump type Woodward L'Orange
Engine rpm 1000 1200 1000 1200
Engine power rating 90 (kW/cyl)
100 (kW/cyl)
110 (kW/cyl)
90 (kW/cyl)
100 (kW/cyl)
110 (kW/cyl)
Max plunger lift 5.40 mm 5.93 mm 6.04 mm 5.40 mm 5.93 mm 6.04 mm
Requirements: Only to be used with piston crownmarked with:IMO-0664
1 Contact point 2 Lever
3 Fixing screws and discs of enclosing cover used
MAN Diesel & Turbo507-01.20Edition 15
Adjustment of camshaft for valve and injection timing Work CardPage 4 (4)
L16/24
2013.06.19 - version 2008
Safety precautions
Engine stoppedShut-off starting airShut off cooling waterShut off fuel oilShut-off cooling oilStop lub. oil circulationPress Blocking - Reset
Short Description
Dismounting, inspection and/or overhaul, andmounting of valve roller guides.
Starting PositionCylinder unit has been removed from engine anddismantled.
Qualified Manpower
Duration in h : 2Number : 1
Data
Data for pressure and tolerance (Page 500.35)Data for tightening torque (Page 500.40)Declaration of weight (Page 500.45)
Special tools
Plate No. Item No. Note52000 831
Hand ToolsFeeler gauge, 0.1 mm
Replacement and wearing parts
Plate No. Item No. Quantity
MAN Diesel & Turbo
Work CardPage 1 (2) Inspection of valve roller guide
508-01.00Edition 15
L16/24
2011.12.12.
Inspection of Valve Roller Guides
1) Turn the water jacket upside down so the rollerguides can slip out at the water jacket.
2) Examine the surface of the roller and the tappethousing for marks and secures, if any they mustbe polished away.
3) Blow clean the lubricating ducts in the tappethousing and the roller with air.
4) Examine the push rod, pin and ball cup fordamage and replace if necessary.
Replacement of roller and shaft pin
1) Remove the lock screw.
2) Push out the axle. The roller and axle can now be replaced.
1) Mount item 2-3-4-5 on the water jacket assem-bly, see fig 1.
2) Press the two guides together, and slightlytighten the two M6 bolts (item 5).
3) Turn the tappets so that the plane surfacespoint towards each other, and mount them inthe water jacket.
Adjustment of guides for tappets
1) Final adjustment of guide-tappet clearance canonly be done after the cylinder unit has beeninstalled on the engine and cylinder cover nutsare tightened.
2) Turn the actual cylinder into overlap top deadcentre. (Both inlet- and exhaust valve has lifteda few millimetres and the cams are now aligningthe roller in correct position)
Figure 2: Brackets between roller guides
3) Put 0,1 mm feeler gauge on both sides of theguides and untighten the two M6 bolts (5).Make sure that there is full parallel contact onthe feeler gauges. Tighten the two M6 bolts seefig. 2. (Re-check the feeler gauges has parallelcontact and make sure the clearance betweenguide and tappet is 0.1 mm +0.1 / - 0) Removethe feeler gauges.
4) Turn the engine so that both rollers are on thecircular part of the cams. Check that the tap-pets can turn free from side to side in the clear-ance. Adjustment is completed.
MAN Diesel & Turbo508-01.00Edition 15
Inspection of valve roller guide Work CardPage 2 (2)